Cross member in a hybrid construction and method of making same

ABSTRACT

A cross member in a hybrid motor vehicle construction is arranged between A-columns of a motor vehicle. The cross member has a basic body which is widened in a center area at least on one side and is designed as part of a housing of a heating and/or air conditioning system.

BACKGROUND AND SUMMARY OF THE INVENTION

[0001] This application claims the priority of German Patent Document100 14 606.6, filed Mar. 24, 2000, the disclosures of which is expresslyincorporated by reference herein.

[0002] The invention relates to a cross member in a hybrid construction,particularly for an arranging between the A-columns of a motor vehicle,which has a shell-shaped basic body, which is reinforced by means ofinjection-molded-on ribs made of a plastic material and in which atleast one air conducting duct is provided.

[0003] Members in a hybrid construction, which can also be used forvehicle parts, are basically known from European Patent Document EP 0370 342 B1.

[0004] A cross member of the initially mentioned type is known, forexample, from German Patent Document DE-U 299 16 466. In thisconstruction, the air conducting ducts are pulled as prefabricatedtube-shaped structures after the manufacturing of the cross member underthe plastic ribbing.

[0005] It is an object of the invention to construct a cross member ofthe initially mentioned type such that it can take over additionalfunctions.

[0006] This object is achieved according to preferred embodiments of theinvention in that the basic body is widened in the center area at leaston one side and is designed as part of a housing of a heating or airconditioning system.

[0007] As a result of this construction, it is possible to use the crossmember also as an importing supporting element for a heating and airconditioning system.

[0008] As a further development of certain preferred embodiments of theinvention, it is provided that the air conducting ducts are molded intothe cross member in one piece with the ribs and lead into the widenedarea. This permits a further simplification, in which case the airconducting ducts are also used as reinforcing elements.

[0009] As a further development of certain preferred embodiments of theinvention, the basic body is reinforced in the widened area by at leastone inserted component. This component is expediently fixed to the basicbody before the latter is placed in the injection mold. The plasticmaterial injected for reinforcing the basic body can then ensure thatthis inserted component is completely fixed. However, the insertedcomponent can also be fixedly mounted on the basic body, for example, bewelded to the basic body, such that a fixing by means of the injectedplastic material is not required. Cold processes, such a riveting,locking, or the like, are also suitable for this fixing.

[0010] Advantageously, according to certain preferred embodiments of theinvention, connections for air outlet nozzles are molded to the basicbody in the widened area. These connections are therefore connecteddirectly with a part of the housing of the heating or air conditioningsystem, so that no internal lines or the like have to be laid.

[0011] As a further development of certain preferred embodiments of theinvention, it is provided that receiving devices and/or fasteningelements for components to be arranged in the area of an instrumentpanel are molded to the exterior side of the basic body. Thus, the crossmember is utilized as a main supporting element for the instrumentpanel. In this case, it is expedient for additional reinforcing elementsfor the basic body to be provided in the area of the receiving devicesand/or fastening elements. These additional reinforcing elements can besubsequently mounted profiles or so-called “tailored blanks”. It is alsopossible to reinforce, for example, before the insertion into theinjection mold, the walls in the area of the receiving devices and/orfastening elements by means of insertion plates and/or bending, foldingor corrugating or the like.

[0012] Other objects, advantages and novel features of the presentinvention will become apparent from the following detailed descriptionof the invention when considered in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 is a top perspective view of a cross member according topreferred embodiments of the invention in a hybrid construction withsome of the components mounted thereon;

[0014]FIG. 2 is an enlarged sectional view of the cross member alongLine II-II of FIG. 1;

[0015]FIG. 3 is a sectional view of the embodiment according to FIG. 1along Line III-III which is shown not quite as enlarged;

[0016]FIG. 4 is a sectional view of FIG. 1 along Line IV;

[0017]FIG. 5 is a sectional view along Line V-V of FIG. 1;

[0018]FIG. 6 is a sectional view of an end area of a modified embodimentof a cross member; and

[0019] FIGS. 7 to 9 are cross-sectional views of additional embodimentsfor cross members in a hybrid construction.

DETAILED DESCRIPTION OF THE DRAWINGS

[0020] The cross member 10 illustrated in FIG. 1 is arranged in usebetween the A-columns of a motor vehicle and is utilized not only as asupporting construction but also as a functional component foradditional devices, particularly for the heating and/or air conditioningsystem of the motor vehicle. On the cross member 10, a housing 11 of theheating or air conditioning system is mounted which, toward the front,has transversely extending flow ducts 12 for a defrosting device for awindshield. Furthermore, the cross member 10 is used for fastening theprotective casing tube 13 to a bearing block or fastening component of asteering column on the driver side as well as for mounting an air bag 14on the passenger side. In addition, the cross member 10 forms two airducts which originate from the center area and lead to the lateralnozzles 15. From the center area of the cross member, which adjoins thehousing 11, center nozzles 16, so-called person-directed flow nozzles,lead to the vehicle interior. Furthermore, upward-directed cold-airnozzles 17 start out in the area of the housing 11 from the cross member10, which cold-air nozzles 17 have the purpose of blowing out cold airin the upward direction which will then flow along the vehicle roof intothe rearward area of the vehicle occupant compartment, that is, to therear seat row.

[0021] The basic shape of the cross member 10 in the hybrid constructionis illustrated in the cross-sectional view of FIG. 2. It is formed of ashell-shaped basic body 18 which is made of metal, for example, aluminumor steel, or of a plastic material. This basic body 18 is placed in aninjection mold and is then reinforced by a plastic material which isinjected into the injection mold. When a basic body 28 made of plasticis used, it is expedient for recycling reasons to use the same plasticmaterial for the injection. Polypropylene or polyamide or polyurethaneor other thermoplastics can preferably be used as the plastic materialand can optionally be reinforced by glass fibers or carbon fibers or thelike. The basic body 18 has a semi-cylindrical basic shell 19, whoseedges are adjoined by legs 20, 21. For the reinforcement, the distancebetween the legs 20, 21 is bridged by means of plastic material whichforms rhombic reinforcing ribs which cross one another approximately inthe center 22. The plastic material reaches around the edges of the legs20, 21 bent toward the outside. Likewise, transversely extending webs orcombinations of different ribbings can be provided.

[0022] In addition to the shell-shaped basic body 18, cores are insertedin the injection mold, so that tube-shaped air conducting ducts 23 areinjection-molded in the interior. In this embodiment, the air conductingducts 23 are formed completely of plastic walls. As also illustrated inFIG. 2, the legs 20, 21 of the basic body 18 are bent toward the outsidestarting from the edges of the semi-cylindrical part 19, so that coresof a suitable shape can be inserted for forming the rhombic ribbing.

[0023] At several points, the shell-shaped basic body 18 is providedwith openings, so that the plastic material will form-lockingly connectwith the shell-shaped basic body 18. In the embodiment shown, a rib 24,which extends in the longitudinal direction, is provided in the centeron the exterior side of the shell-shaped basic body 18. This rib 14 ispreferably connected in a regularly spaced manner through openings withthe plastic material injection-molded to the inside. In particular, aswill be explained in the following, fastening elements made of plasticare created at several points on the exterior side of the cross member10. As also illustrated in FIG. 2, the cross member 10 in the hybridconstruction is arranged such that the legs 20, 21 point at an angle ofpreferably approximately 45° diagonally toward the front to the forwardend of a vehicle. The angle depends on the orientation of the steeringcolumn, the air bag and the air conditioner and can therefore also havedifferent sizes.

[0024] In the area of the steering column, which is illustrated indetail in FIG. 3, the bent edges of the legs 20, 21 of the cross member10 are widened in the area of fastening points, so that they canaccommodate holes for fastening screws 25. In the area of thesewidenings, webs 26, 27 made of plastic are injection-molded to theoutside of the legs 20, 21. In a modified embodiment, the webs 26, 27are formed as corrugations from the basic body 18. On these widened,bent ends, a plate 28, preferably made of sheet metal, is mounted forreinforcing this area. In this area, the cross member 10 is thenconnected by means of a bridge 28 with the forward front wall of thevehicle. This bridge is designed as a sheet metal construction in theform of a box-shaped profile. The steering column 13 is fastened to thisbridge and thus also to the cross member 10, which steering column, inthe embodiment shown, can be adjusted and fixed in the longitudinaldirection and in the transverse direction. In the area illustrated inFIG. 3, a holding element 29 made of plastic is also injection-molded tothe outside of the cross member 10, which holding element 29 forms adetent for a hook-shaped fastening element 30 of a speedometer 31 or aninstrument cluster, which is suspended at the cross member at thispoint. An additional fastening takes place by means of screws on aholder 32, which is also fastened to the cross member 10, and preferablyin the area of the widened bent end of the web 21.

[0025]FIG. 3 illustrates an air outlet nozzle 16, a so-calledperson-directed flow nozzle, which is also injection-molded in one piecefrom the plastic material.

[0026] As illustrated in FIG. 1 and particularly in FIG. 4, the crossmember 10 is widened in its center area; that is, the basic body 18 hasa changed cross-section in this area. Instead of the leg 21, a wall 33extends diagonally upward which then merges into an approximatelyhorizontal section 34. Instead of the leg 20, a diagonallydownward-directed wall 35 is provided. As illustrated in FIG. 1,transition pieces adjoin the walls 33, 34, 35 and connect the lateralends of the center area again with the legs 20, 21 of the cross member10. The center nozzles 16 or person-directed flow nozzles as well as theupper cold-air nozzles 17 adjoin this widened area of the cross member10. This widened area of the cross member 10 is reinforced by means ofinserts which are not shown in detail. In particular, an insertion,which has a triangular cross-section, is provided in the center plane,consists, for example, of the same material as the basic body 18 of thecross member and is connected with the latter by welding, gluing or thelike.

[0027] The widened area of the cross member 10 is constructed as a partof a housing of a heating and air conditioning system, as illustrated inFIG. 4. This multi-part housing 36, 37, which contains an evaporator 38and a heater 39, is sealingly fastened to the surrounding edge 40 of thewidened section of the cross member 10. One of the housing parts 36 or37 is preferably constructed in one piece with the plastic ribbing ofthe cross member 10.

[0028] As illustrated in FIG. 5, the cross member 10 is reinforced bymeans of a sheet metal insert 41 in the front passenger area forreceiving an air bag 14. This sheet metal insert has a U-shaped partwhose legs are fitted into the recesses between the ribbing and areconnected with the legs 20, 21 by means of screws. A holder 42 of theair bag housing is simultaneously fastened to the leg 21. As illustratedin FIG. 5, in this area, the cross member is reinforced by plasticpreforms 43, 44 injection-molded to the outside. These plastic preforms,which are provided in a regularly spaced manner on the outside of thecross member, are provided with noses 45, 46 which are used as aninsertion groove for cables 47, 48 extending along the cross member 10,which cables 47, 48 are fastened by means of clamps 49.

[0029] Furthermore, plastic holding devices are molded to the crossmember 10 in the front passenger area, on which plastic holding devicesthe housing 50 of a glove compartment is fastened.

[0030] The A-columns of the vehicle are provided with consoles 51 onwhich the cross member 10 is fastened, for example, in the mannerillustrated in FIG. 6. Also in this area, the bent edges of the legs 20,21, around which plastic material is injected-molded, are widened andare provided with fastening holes, so that they can be connected in aflange-type manner on the console 51 by means of screws. The console isprovided with a profiling 52 which penetrates into the recesses betweenthe ribbing of the cross member and is adapted to the rounding of theair conducting duct 23.

[0031] Since the cross member 10 is to be securely held in the area ofthese consoles 51, it is additionally reinforced in this area by anouter ribbing 53, which is also produced in the injection molding die orby a shaping of the basic body 18.

[0032] For cross members in the hybrid construction, which permit awidening in the center area forming part of a heating or airconditioning system housing, in addition to the form illustrated inFIGS. 1 to 6, other advantageous shapes exist, for example, the shapeillustrated in FIGS. 7 to 9. The cross member 10′ has a shell-shapedbasic body 18′ with a U-shaped cross-section which is reinforced betweenthe legs by the injection of plastic material in an injection moldingdie, preferably in a rib shape. Together with the transverse web of theU-shaped basic body 18′, this plastic material forms a one-piece airduct 37′, in which case a wall is formed by the basic profile 18′. Theillustration according to FIG. 9 shows sections on both sides of thedash-dotted line, which are offset by a division of the rhombic ribbing.

[0033] As illustrated, for example, in FIGS. 7 and 8, the cross member10′ can be widened in the center area such that it is virtually doubledin this area. In the embodiment according to FIG. 7, the shell-shapedbasic body 18″ has a meandering profile, while in the embodimentaccording to FIG. 8, two basic bodies 18′ of the embodiment of FIG. 9are arranged side-by-side.

[0034] The foregoing disclosure has been set forth merely to illustratethe invention and is not intended to be limiting. Since modifications ofthe disclosed embodiments incorporating the spirit and substance of theinvention may occur to persons skilled in the art, the invention shouldbe construed to include everything within the scope of the appendedclaims and equivalents thereof.

What is claimed:
 1. Cross member disposable in use between A-columns ofa motor vehicle, which has a shell-shaped basic body reinforced byinjection-molded-on ribs made of a plastic material and in which atleast one air conducting duct is provided, wherein the basic body iswidened in a center area at least on one side and is designed as part ofa housing of a heating and/or air-conditioning system.
 2. Cross memberaccording to claim 1 , wherein the air conducting ducts are molded intothe cross member and lead into the widened area.
 3. Cross memberaccording to claim 1 , wherein injected plastic material forms an airconducting duct at said cross member, said air conditioning duct beingproduced of plastic on all sides.
 4. Cross member according to claim 1 ,wherein plastic material forms only a part of walls of air conductingducts, and wherein supplementary wall sections are formed by the basicbody.
 5. Cross member according to claim 1 , wherein the basic body isreinforced in the widened area by at least one inserted component. 6.Cross member according to claim 1 , wherein connections for air outletnozzles are molded in the widened area to the basic body.
 7. Crossmember according to claim 1 , wherein the basic body is provided withrecesses, in whose area tube-shaped connection pieces to at least oneair conducting duct are molded on by means of the plastic material. 8.Cross member according to claim 1 , wherein receiving devices and/orfastening elements for components to be arranged in an area of aninstrument panel are molded to the exterior side of the basic body. 9.Cross member according to claim 8 , wherein additional reinforcingelements for the cross member are provided in an area of the receivingdevice and/or the fastening elements.
 10. Cross member according toclaim 1 , wherein the basic body has an essentially C-shaped or U-shapedcross-section, whose legs point diagonally downward and forward. 11.Cross member according to claim 10 , wherein the legs are bent to theoutside and are widened in an area of fastening points.
 12. Cross memberaccording to claim 10 , wherein the legs in the area of fastening pointsare provided with reinforcing ribs on the exterior side.
 13. Crossmember according to claim 2 , wherein injected plastic material forms anair conducting duct at said cross member, said air conditioning ductbeing produced of plastic on all sides.
 14. Cross member according toclaim 13 , wherein plastic material forms only a part of walls of airconducting ducts, and wherein supplementary wall sections are formed bythe basic body.
 15. Cross member according to claim 14 , wherein thebasic body is reinforced in the widened area by at least one insertedcomponent.
 16. Cross member according to claim 15 , wherein connectionsfor air outlet nozzles are molded in the widened area to the basic body.17. Cross member according to claim 16 , wherein the basic body isprovided with recesses, in whose area tube-shaped connection pieces toat least one air conducting duct are molded on by means of the plasticmaterial.
 18. Cross member according to claim 17 , wherein receivingdevices and/or fastening elements for components to be arranged in anarea of an instrument panel are molded to the exterior side of the basicbody.
 19. Cross member according to claim 18 , wherein additionalreinforcing elements for the cross member are provided in an area of thereceiving device and/or the fastening elements.
 20. A cross member for amotor vehicle comprising: a hollow shell shaped basic body defining atleast one vehicle air conditioning duct, said basic body including awidened section in a region intermediate ends of the basic body, whichwidened section forms part of a vehicle heating and/or air conditioningsystem when an in use position with said basic body connected betweenmotor vehicle body columns.
 21. A cross member according to claim 20 ,wherein said basic body is formed of plural shell parts connectedtogether.
 22. A cross member according to claim 20 , comprising plasticmaterial reinforcing ribs injection molded on the basic body.
 23. Across member according to claim 20 , wherein said basic body is made ofinjection molded plastic material.
 24. A passenger vehicle assemblycomprising: vehicle body A-columns at respective opposite lateral sidesof a vehicle passenger space, and a cross member with respectiveopposite ends connected to the respective A-columns, said cross memberincluding: a hollow shell shaped basic body defining at least onevehicle air conditioning duct, said basic body including a widenedsection in a region intermediate ends of the basic body, which widenedsection forms part of a vehicle heating and/or air conditioning systemwhen an in use position with said basic body connected to the A-columns.25. A passenger vehicle assembly according to claim 24 , wherein saidbasic body is made of injection molded plastic material, wherein saidbasic body is formed of plural shell parts connected together, andwherein plastic material reinforcing ribs are injection molded on thebasic body.
 26. A passenger vehicle assembly according to claim 24 ,comprising a vehicle steering assembly supported at said cross member.27. A method of making a vehicle cross member, comprising: providing ashell-shaped basic body adapted to be connected to vehicle A-columns andincluding a hollow section for at least one air conditioning duct, andforming reinforcing ribs an the basic body by injection molding plasticthereon, wherein the basic body is widened in a center area at least onone side and is designed as part of a housing of a heating and/orair-conditioning system.